General overview
Short for generator set, a genset is a piece of portable equipment, consisting of an engine and an alternator/electric generator to generate electrical energy. It is a vital equipment that provides power and backup electricity in several industries. Gensets are often used in places that do not have grid access, for projects that require more energy than the grid can provide or for situations where power certainty is so important that a backup is required in case of grid failure. By implementing 101 Solutions remote monitoring system, 101Connect, users can acquire a dashboard view of their gensets for power generation, state of charge, fuel level, equipment up-time, system failures, trend analyses, logging data, etc.
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| Genset | 101Connect dashboard view |
Problem-solving
Gensets are used in industrial processes where high reliability is a must. As they are often not connected to the mains, it is a requirement that they are remotely monitored for status deviations and that the monitoring staff can be notified in real-time of such status changes. To monitor the condition of the gensets, a data acquisition hardware must be installed that can connect to and communicate with PLC, HMI or controllers, while a remote mobile connection must be established to connect to hub/web portal. On top of all the technical specification requirements mentioned, the “hardware” must also be rugged enough to survive the harsh environmental conditions it is deployed in. Environmental conditions such as heat under the sun, wide-range power input for compatibility, shock and vibration during mobile conditions.
Problem-solved – The 101Connect with Neousys IGT Series
Why Neousys Technology IGT
101 Solutions found the “hardware” in Neousys Technology IGT20, a rugged ARM-based wide-temperature industrial IoT gateway with rich I/Os, COM ports, LAN, SIM slot for wireless communication. Neousys Technology's long track record in industrial applications and reputation in providing good aftersales support service were also points of consideration.
101Connect integration
Integrating the Neousys IoT gateway IGT series into 101 Solutions system, the 101Connect, enabled remote monitoring and control of gensets. The preconfigured IGT system can connect remotely to an HMI/PLC/controller via a secured VPN connection.
Predictive maintenance
From research, approximately 18% of causes of failures are age-of-machinery related while up to 82% arise from random failure. With historic data recording, the system can analyze for recognizable patterns to predict possibilities of a failure to avoid system downtime.
Alarm management
Customers can monitor and signal deviations beyond the preset figures, or manually customized settings in real-time employing event & alarm management via the web portal.
The hardware
With the combination of the IGT-20 series supplemented with a modem and modular software developed by 101 Solutions, the customized solution can also be developed for various applications, such as twin sets, hybrid systems with solar panels, fuel cells, battery packs and cooling systems.
Accounts and authorization
The system allows for unlimited accounts to be created for employees, customers, service personnel, etc., each with its system authorization.
Together, they offer the following benefits:
- Plug & play and preconfigured hardware
- 24/7 operation to monitor generators
- VPN connection for remote monitoring, remote configuration or remote programming
- Adjustable online dashboards, trends, graphs, reports and alarms via web portal
- In addition, Node-Red is available for customers who want to set up their configurations
Benefits of Neousys IGT industrial gateway
Neousys Technology's IGT industrial-grade IoT gateway has the following benefits:
Environmental
- True -25°C up to 70°C wide-temperature operations for harsh, volatile environments
- Shock (up to 50Grms) and vibration (up to 5Grms) resistant
Connectivity/ expandability
- USB connectivity
- Ethernet connectivity (PoE+ PD capable)
- WiFi/ 5G/ 4G wireless communication, expansion via mini-PCIe module
Input/ output interface
- Isolated digital input
- Isolated digital output
- CAN bus
- User-programmable buttons
IGT customization
- OS customization
- Connectivity customization
- Brand/ logo customization
